JP2024504943A - Method, mold system, and cellulose blank structure for forming cellulosic products from a cellulose blank structure in a mold system - Google Patents

Abstract

A method for forming a cellulose product from an air-formed cellulose blank structure (2) in a mold system, the mold system comprising one or more molds (3). . Each mold has a first mold part (3a) and a second mold part (3b) configured to cooperate with each other during molding of the cellulosic product. The method includes the following steps: providing a cellulosic blank structure, in which the cellulosic blank structure is provided with one or more product segments (2a) and surrounding or surrounding the one or more product segments. compressing at least a portion of the residual section to a first degree of compaction that is higher than the degree of compaction of the one or more product sections; cellulose; Feeding the blank structure in a feeding direction to a forming position in the mold system, wherein each product section is disposed between a corresponding first mold part and a second mold part. step; by heating the cellulose blank structure to a forming temperature in the range of 100 to 300°C and pressing the cellulose blank structure at a forming pressure in the range of 1 to 100 MPa, preferably 4 to 20 MPa; forming a cellulose product from a cellulose blank structure between a first mold section and a second mold section.

Description

The present disclosure relates to a method for forming cellulosic products from an air-formed cellulosic blank structure in a mold system. The mold system includes one or more molds, each mold having a first mold portion and a second mold portion configured to cooperate with each other during molding of the cellulosic product. have. The present disclosure further relates to mold systems and cellulose blank structures.

BACKGROUND OF THE INVENTION Cellulose fibers are often used as raw materials for manufacturing or making products. Products formed from cellulose fibers can be used in many different situations where there is a need to have a sustainable product. A wide range of products can be manufactured from cellulose fibers, some examples are disposable plates and cups, cutlery, lids, bottle caps, coffee pods, and packaging materials.

Molding molds are commonly used in producing cellulose products from raw materials containing cellulose fibers, and traditionally cellulose products have been produced by wet molding techniques. A commonly used material for wet molding of cellulosic fiber products is wet molded pulp. Wet-molded pulp has the advantage of being considered a sustainable packaging material because it is made from biomaterials and can be recycled after use. As a result, wet-molded pulp is rapidly gaining popularity for a variety of applications. Wet-formed pulp articles are generally formed by dipping a suction mold into a liquid or semi-liquid pulp suspension or slurry containing cellulose fibers, and when suction is applied, the pulp mass is forced into the mold. The desired product shape is formed by fiber deposition into the desired product shape. All wet molding techniques require drying of the wet molded product, and such drying is an extremely time and energy consuming part of production. The demands on the aesthetic, chemical and mechanical properties of cellulosic products are increasing, and the properties of wet-formed cellulosic products have increased mechanical strength, flexibility, flexibility in material thickness, and chemical properties. has limitations. In addition, in the wet molding process, it is difficult to control the mechanical properties of the product with high precision.

One development in the field of cellulosic product manufacturing is the molding of cellulose fibers without the use of wet molding techniques. Instead of forming cellulosic products from liquid or semi-liquid pulp suspensions or slurries, air formed cellulose blank structures are used. An air-formed cellulosic blank structure is inserted into a mold, and the cellulose blank is subjected to high molding pressures and high molding temperatures during molding of the cellulosic product. When inserting the cellulose blank structure into the mold, there is a risk that the cellulose blank structure will be destroyed in an undesirable manner, leading to improper shaping of the cellulosic product. This is a common problem with traditional cellulose high pressure forming processes, especially for deep drawn products, resulting in a poor quality product. Other problems with conventional forming methods using standard cellulose blank structures, especially when forming deep-drawn products, are that cracks, fiber separation, material failure, or other undesirable structural weakening of the cellulose blank structure may occur. , which occur during the insertion of the cellulosic blank structure into the mold and during the molding process in the mold.

Accordingly, there is a need for improved methods, mold systems, and cellulosic blank structures for forming cellulosic products from air-formed cellulosic blank structures.

SUMMARY It is an object of the present disclosure to provide a method, a mold system, and a cellulosic blank structure for forming cellulosic products from a cellulose blank structure in a mold system that avoids the problems described above. This object is solved at least in part by the features of the independent claims. The dependent claims contain further improvements in the method for forming cellulosic products from a cellulosic blank structure in a mold system.

The present disclosure relates to a method for forming cellulosic products from an air-formed cellulosic blank structure in a mold system. The mold system includes one or more molds, each mold having a first mold portion and a second mold portion configured to cooperate with each other during molding of the cellulosic product. have. The method includes the following steps: providing a cellulosic blank structure, including one or more product segments surrounding or connected to the one or more product segments. compressing at least a portion of the residual section to a first degree of compaction that is higher than the degree of compaction of the one or more product sections; a cellulose blank structure; feeding a cellulose blank structure into a molding position in a mold system, wherein each product section is disposed between a corresponding first mold part and a second mold part; The first mold part and the second mold part are heated to a molding temperature in the range of 100 to 300°C and by pressing the cellulose blank structure at a molding pressure in the range of 1 to 100 MPa, preferably 4 to 20 MPa. molding a cellulose product from the cellulose blank structure between the two mold parts.

The advantage of including these features is that the risk of the cellulose blank structure being destroyed in an undesirable manner during transport and insertion into the mold is prevented. This solution results in good shaping of cellulosic products with improved product quality, especially for deep-drawn products. Cracking, fiber separation, material fracture, or other undesirable structural weakening of the cellulose blank structure upon insertion into the mold and during the forming process in the mold can be avoided by this method, resulting in product classification. Minimized by molding and residual section. Transport of the cellulosic blank structure is facilitated by the residual section being compressed to a first degree of compaction that is higher than the degree of compaction of one or more product sections; It allows transport of cellulose blank structures at relatively high feed rates without destroying the body. A product section with a relatively low degree of compaction allows for flexible fiber transport into the mold. Relatively high feed rates reduce product molding cycle time.

According to one aspect of the present disclosure, the cellulosic blank structure further includes one or more transition sections disposed between the one or more product sections and the remainder section. In one or more transition segments, the degree of compression changes between the first degree of compression and the degree of compression of one or more product segments. The transition section forms a structure that supports the transport of the fibers into the mold. The transition section further prevents fiber breakage in the cellulosic blank structure between the product section and the remainder section.

According to another aspect of the present disclosure, the method includes the step of compressing at least a portion of the one or more product sections to a second degree of compression prior to feeding the cellulosic blank structure to a forming position. In this case, the first degree of compression further has a higher step than the second degree of compression. The degree of second compaction may vary for different types of products being molded, with products that are drawn deeper often requiring a relatively lower degree of compaction.

According to one aspect of the present disclosure, the method includes, prior to forming a cellulosic product, positioning a residual section and one or more product sections relative to each other in the pressing direction of a mold system at a forming position. Further comprising the step of at least partially displacing. This displacement facilitates the shaping of cellulosic products, especially for deep-drawn products, where the fibers within the cellulose blank structure are allowed to move relative to each other.

According to another aspect of the disclosure, the method further comprises disposing a cutting pattern at least partially in a residual section and/or a transition section around each product section. Each cutting pattern forms at least one bridge structure in the residual section and/or the transition section for keeping each product section partially connected to the residual section and/or the transition section. The cutting pattern supports shaping of the cellulosic product, where the product sections are movable relative to the remainder of the cellulosic blank structure. The bridge structure effectively maintains the position of the product section relative to the mold during the product molding operation.

According to a further aspect of the present disclosure, each cutting pattern has non-continuous first cuts connected to and disposed about the corresponding product section. The discontinuous first cutting section has one or more first cutting lines, and the first cutting line has one or more first cutting lines between the one or more first cutting lines. It has a first intermediate section. The one or more first intermediate sections form at least one bridge structure. A cutting pattern having such a configuration is easy to design.

According to one aspect of the present disclosure, each cutting pattern has a first cut connected to and disposed about the corresponding product section. The first cut has a first cut line with a first intermediate section forming at least one bridge structure.

According to another aspect of the disclosure, each cutting pattern includes a non-continuous first cut connected to and disposed about a corresponding product segment and a non-continuous first cut connected to and disposed about a corresponding product segment; and a discontinuous second cut section disposed outside and around the continuous first cut section. The first cut and the second cut effectively cooperate to form at least one bridge structure.

According to a further aspect of the disclosure, the non-continuous first cut has one or more first cut lines, and the first cut line has one or more first cut lines. It has one or more first intermediate sections between the cutting lines. The discontinuous second cut has one or more second cut lines, and the second cut line has one or more cuts between the one or more second cut lines. It has a second intermediate section. The one or more first intermediate sections and the one or more second intermediate sections form at least one bridge structure. Such type of cutting pattern effectively allows displacement of the product section relative to the rest of the cellulosic blank structure during the forming operation of the product and is suitable for deep drawn products.

According to one aspect of the present disclosure, the first non-continuous cut and the second non-continuous cut are arranged in a relatively overlapping relationship with each other. The one or more first cutting lines overlap the one or more second intermediate sections, and the one or more second cutting lines overlap the one or more first intermediate sections. are doing.

According to another aspect of the disclosure, each cut pattern includes at least one non-continuous addition disposed outside and around the non-continuous second cut relative to the product segment. It further has a cutting part. Each of the at least one discontinuous additional cut has one or more additional cut lines, and the additional cut lines are between the one or more additional cut lines. It has one or more additional intermediate sections. Such type of cutting pattern effectively allows displacement of the product section relative to the rest of the cellulosic blank structure during the forming operation of the product and is suitable for deep drawn products.

According to a further aspect of the disclosure, each cut extends through the cellulosic blank structure. In this way, each cut forms an opening in the cellulosic blank structure for effective displacement of the product section.

According to one aspect of the present disclosure, at least one of the intermediate sections has a cut that extends partially through the cellulosic blank structure. The partially extending cut can support positioning of the product section relative to the mold during transport of the cellulosic blank structure.

According to another aspect of the disclosure, the method further comprises placing one or more cutting patterns in a residual section and/or a transition section around each product section by the cutting unit. The cutting unit is used to form the cutting pattern and may have different structures, such as a rotary die cutter or a press cutting device.

According to a further aspect of the disclosure, the cutting unit is arranged as a rotary die cutter. The method includes forming one or more cutting patterns and compressing at least a portion of the residual section by a rotary die cutter in a single operational step; or by a rotary die cutter in a single operational step. , forming one or more cutting patterns and compressing at least a portion of the remaining sections, and compressing at least a portion of the one or more product sections.

According to an aspect of the present disclosure, the method further comprises cutting the cellulosic product from the cellulosic blank structure in a mold system during molding of the cellulosic product. This method allows the cellulosic product to be cut from the cellulosic blank structure directly connected to the mold while the cellulosic blank structure is placed in the molding position.

According to another aspect of the disclosure, product segments are arranged on a cellulosic blank structure in a pattern that corresponds to the arrangement of one or more molds in a mold system.

The cellulosic blank structure may be conveyed in the feed direction by one or more feed belts. The feed belt provides an efficient and simple means of transporting the cellulosic blank structure.

The present disclosure further relates to mold systems for molding cellulosic products from air-formed cellulosic blank structures. The cellulosic blank structure has one or more defined product segments and a defined residual segment that surrounds the one or more product segments or is located in connection with the one or more product segments. ing. The mold system includes one or more molds, each mold having a first mold portion and a second mold portion configured to cooperate with each other during molding of the cellulosic product. have. a compact unit configured to compress at least a portion of the residual section to a first degree of compaction that is higher than the degree of compaction of the one or more product sections; and a cellulosic blank structure in a feed direction. The apparatus further includes a supply unit configured to supply a molding position within the mold system. In the molding position, each product section is located between a corresponding first and second mold section. The one or more molds are formed by heating the cellulose blank structure to a forming temperature in the range of 100 to 300°C and pressing the cellulose blank structure at a forming pressure in the range of 1 to 100 MPa, preferably 4 to 20 MPa. By doing so, the cellulose product is formed from the cellulose blank structure between the first mold part and the second mold part. An advantage of including these system features is that the risk of undesirable destruction of the cellulosic blank structure during insertion into the mold is prevented. This solution provides good shaping of cellulosic products, especially for deep-drawn products.

The present disclosure further relates to cellulose blank structures for forming cellulosic products in mold systems. The cellulosic blank structure is air formed and has one or more defined product segments and a defined product segment surrounding or connected to the one or more product segments. It has a residual classification. At least a portion of the remaining sections have a first degree of compression that is higher than the degree of compression of the one or more product sections. The cellulosic blank structure further includes one or more transition sections disposed between the one or more product sections and the remainder section. In the transition segment, the degree of compression changes between the first degree of compression and the degree of compression of one or more product segments. The cellulosic blank structure further has a cutting pattern at least partially around each product section, in the residual section and/or the transition section. Each cutting pattern forms at least one bridge structure in the residual section and/or the transition section. Cracks, fiber separation, material fractures, or other undesirable structural weakening of the cellulose blank structure during insertion into the mold and during the forming process in the mold are eliminated by the system, resulting in product classification. Minimized by molding with and residual section. Transport of the cellulosic blank structure is facilitated by the residual section being compressed to a first degree of compaction that is higher than the degree of compaction of one or more product sections.

The present disclosure will be described in detail below with reference to the accompanying drawings.

1 is a perspective view schematically illustrating a cellulose blank structure according to the present disclosure; FIG. 1 is a perspective view schematically illustrating a mold system with a compact unit according to the present disclosure; FIG. 1 is a perspective view schematically illustrating a cellulose blank structure with a cutting pattern according to the present disclosure; FIG. 1 is a perspective view schematically illustrating a mold system with a cutting unit according to the present disclosure; FIG. 1 is a perspective view schematically illustrating a mold system with a cutting unit according to the present disclosure; FIG. 1 is a plan view schematically illustrating a cellulose blank structure with a cutting pattern in a multi-cavity structure according to the present disclosure; FIG. 1 is a front view schematically illustrating a cellulose blank structure with a cutting pattern in a multi-cavity structure according to the present disclosure; FIG. 1 is a plan view schematically illustrating a cellulose blank structure with a cutting pattern in a single cavity structure or in a section of a multi-cavity structure according to the present disclosure; FIG. 1 is a front view schematically illustrating a cellulose blank structure with a cutting pattern in a single cavity structure or in a section of a multi-cavity structure according to the present disclosure; FIG. 1 is a front view schematically illustrating a mold system according to the present disclosure; FIG. 1 is a front view schematically illustrating a mold system according to the present disclosure; FIG. 1 is a front view schematically illustrating a mold system according to the present disclosure; FIG. 1 is a front view schematically illustrating a mold system according to the present disclosure; FIG. 1 is a front view schematically illustrating a mold system according to the present disclosure; FIG. 1 is a perspective view schematically illustrating a mold system shown without a first mold portion and a supply unit with a supply belt according to the present disclosure; FIG. 1 is a perspective view schematically illustrating a mold system shown without a first mold portion and a supply unit with a supply belt according to the present disclosure; FIG. 1 is a perspective view schematically illustrating a mold system shown without a first mold portion and a supply unit with a supply belt according to the present disclosure; FIG. 1 is a plan view schematically illustrating a cellulose blank structure with a cutting pattern according to the present disclosure; FIG. 1 is a plan view schematically illustrating a cellulose blank structure with different cutting patterns according to the present disclosure; FIG. 1 is a plan view schematically illustrating a cellulose blank structure with different cutting patterns according to the present disclosure; FIG. 1 is a plan view schematically illustrating a cellulose blank structure with different cutting patterns according to the present disclosure; FIG. 1 is a plan view schematically illustrating a cellulose blank structure with different cutting patterns according to the present disclosure; FIG. FIG. 3 is a perspective view schematically illustrating a cellulose blank structure according to an alternative embodiment of the present disclosure. FIG. 3 is a perspective view schematically illustrating a mold system according to an alternative embodiment of the present disclosure. FIG. 3 is a front view schematically illustrating a mold system according to an alternative embodiment of the present disclosure. FIG. 6 is a front view schematically illustrating a mold system with a cutting unit according to an alternative embodiment of the present disclosure; FIG. 6 is a front view schematically illustrating a mold system with a cutting unit according to an alternative embodiment of the present disclosure;

DESCRIPTION OF EXEMPLARY EMBODIMENTS Various aspects of the present disclosure are described below with reference to the accompanying drawings, which are intended to be illustrative and not limiting of the disclosure, in which case the same designations refer to similar elements, and variations of the described aspects are not limited to the specifically illustrated embodiments, but are applicable to other variations of the disclosure.

Those skilled in the art will appreciate that the steps and functions described herein can be implemented using one or more hardware circuits, by using software operating in conjunction with a programmed microprocessor or general purpose computer, or by using software operating in conjunction with a programmed microprocessor or general purpose computer. It will be appreciated that it may be implemented by using an application specific integrated circuit (ASIC) and/or by using one or more digital signal processors (DSP). Additionally, when the disclosure is described in terms of a method, the disclosure may be implemented in one or more processors and one or more memories coupled to the one or more processors, in which case one or more It is understood that memory stores one or more programs that, when executed by one or more processors, perform the steps, services, and functions disclosed herein.

1b, 2b, 5a-5e and 9a-9b schematically show a mold system S for molding a cellulose product 1 from one air-formed cellulose blank structure 2. . This mold system S comprises one or more molds 3, each mold 3 having a first mold part 3a and a first mold part 3a configured to cooperate with each other during molding of the cellulosic product 1. It has two mold parts 3b. A control unit connected to the mold system S is suitably used to control the various molding steps.

1a, 2a, 3a-3b and 4a-4b schematically show an air-formed cellulose blank structure 2. FIG. Air-formed cellulose blank structure 2 according to the present disclosure refers to a substantially air-formed fibrous web structure made from cellulose fibers. Air forming of the cellulose blank structure 2 means forming the cellulose blank structure in a dry forming process in which the cellulose blank structure 2 is produced by air forming cellulose fibers. When the cellulose blank structure 2 is formed by an air forming process, the cellulose fibers are transported by air as a transport medium and formed into the fiber blank structure 2. This is different from normal papermaking processes or traditional wet forming processes where water is used as a transport medium for cellulosic fibers when forming paper or fibrous structures. In the air forming process, small amounts of water or other substances may optionally be added to the cellulose fibers to change the properties of the cellulosic product, but air is still used as a conveying medium in the forming process. . The cellulose blank structure 2 may, if appropriate, have a degree of dryness that corresponds primarily to the ambient humidity of the atmosphere surrounding the air-formed cellulose blank structure 2. Alternatively, the dryness of the cellulosic blank structure 2 can be controlled to have a suitable dryness level when forming the cellulosic product 1.

The air-formed cellulose blank structure 2 may be formed from cellulose fibers in a conventional air-forming process and may be constructed in a variety of ways. For example, the cellulose blank structure 2 may have a composition in which the fibers are of the same origin or alternatively include a mixture of two or more types of cellulose fibers, depending on the desired properties of the cellulosic product 1. The cellulose fibers used in the cellulose blank structure 2 are strongly bonded to each other by hydrogen bonds during the forming process of the cellulose product 1. As further discussed below, the cellulose fibers may be mixed with other substances or compounds to a certain extent. By cellulose fiber is meant any type of cellulose fiber, such as natural cellulose fiber or manufactured cellulose fiber. The cellulose blank structure 2 may specifically contain at least 95% cellulose fibers, or more specifically at least 99% cellulose fibers.

The air-formed cellulose blank structure 2 may have a single-layer structure or a multi-layer structure. The cellulose blank structure 2 having a single layer structure means a structure formed from one layer containing cellulose fibers. The cellulose blank structure 2 having a multilayer structure means a structure formed from two or more layers containing cellulose fibers, in which case these layers may have the same or different compositions or structures. good.

The cellulose blank structure 2 may have a reinforcing layer comprising cellulose fibers, which reinforcing layer may be arranged as a support layer for the other layers of the cellulose blank structure 2. The reinforcing layer may have a higher tensile strength than other layers of the cellulose blank structure 2. This is to avoid destruction of the cellulose blank structure 2 during forming of the cellulose product 1 if one or more air-formed layers of the cellulose blank structure 2 have a low tensile strength composition. It is effective for The reinforcing layer with higher tensile strength thus acts as a support structure for the other layers of the cellulosic blank structure 2. The reinforcing layer may be of a different composition than the other layers of the cellulosic blank structure, such as a tissue layer comprising cellulose fibers, an airlaid structure with cellulose fibers, or other suitable layer structure. Therefore, the reinforcing layer need not be an air-formed layer. The cellulose blank structure 2 may have two or more reinforcing layers if appropriate.

The one or more air-formed layers of cellulose blank structure 2 are fluffy air-like structures, the cellulose fibers forming this structure being relatively loosely arranged with respect to each other. . The fluffy cellulose blank structure 2 is used for efficient shaping of the cellulose product 1, allowing the cellulose fibers to efficiently shape the cellulose product 1 during the shaping process.

As shown for example in FIGS. 1a, 2a, 3a-3b, 4a-4b, 7a-7e, 8a and 9a-9b, one cellulose blank structure 2 It has the above defined product category 2a and the defined residual category 2b. One or more product sections 2a are defined as areas or parts of the cellulose blank structure 2 that correspond to the positions of one or more molds 3 when forming the cellulosic product 1. The residual section 2b surrounds one or more product sections 2a or is arranged connected to one or more product sections 2a. Before the forming operation in the mold system, at least a portion of the residual section 2b is compressed to a first degree of compression D _C1 which is higher than the degree of compression D _C1 of the one or more product sections 2a, as can be seen from the figure. Compressed. The one or more product sections 2a may not be compressed, or alternatively at least a portion of the one or more product sections 2a is compressed to a second degree of compression D _C2 .

In certain embodiments, the cellulosic blank structure 2 may have one or more defined residual sections 2b, where each residual section 2b surrounds one or more product sections 2a. , or arranged connected to one or more product segments 2a. Before the forming operation in the mold system, at least a portion of the residual section 2b is compressed to a first degree of compression D _C1 that is higher than the degree of compression D _C of the one or more product sections 2a.

As shown in the illustrated embodiment, the residual section 2b is suitably compressed to a first degree of compression D _C1 . The residual section 2b may be compressed to a first degree of compression D _C1 with a density in the range from 40 to 1300 kg/m ³ . The density of the residual section 2b may be measured by cutting a sample piece of material immediately after the cellulose blank structure 2 has been compacted, for example between compacting rollers. The thickness of the sample piece in the residual section 2b is measured with a caliper within 1 minute of compression, after which the sample piece is weighed. The sample piece suitably has a rectangular or circular shape with an area in the range 400-2000 mm ² . When measuring the thickness of a sample piece with a caliper, a pressure of 0.5 kPa is applied to the entire surface of the sample piece. The weight [m] of the sample piece, along with the thickness [t] and area [A], is determined by the formula ρ=m/At
is used to calculate the density [ρ] according to

In FIG. 1a, the first sample piece P1 of the residual section 2b is indicated by a dotted line for illustrative purposes; in the illustrated embodiment, the first sample piece P1 has a rectangular shape. FIG. 1a shows a first area A1 and a first thickness direction T1 of a first sample piece P1.

The residual section 2b may have an embossed pattern on one or both sides, for example a waffle surface-like structure, in order to increase the stiffness and strength of the cellulose blank structure 2.

Cellulose blank structure 2 further comprises one or more transition sections 2c arranged between one or more product sections 2a and residual sections 2b. In the transition section 2c, the degree of compression may vary between a first degree of compression D _C1 and a degree of compression D _C of one or more product sections 2a. The transition section 2c may have other degrees of compression, if appropriate.

In a particular embodiment, the one or more product sections 2a are compressed to a second degree of compaction D _C2 before feeding the cellulosic blank structure 2 to the forming position F _POS . The first degree of compression D _C1 is higher than the second degree of compression D _C2 . The one or more product sections 2a may suitably be compressed to a second degree of compression D _C2 with a density in the range from 15 to 400 kg/m ³ . The density of one or more product sections 2a may be measured by cutting a sample piece of material immediately after the cellulose blank structure 2 has been compacted, for example between compacting rollers. The thickness of the sample pieces of one or more product categories 2a is measured with a caliper within 1 minute of compaction, after which the sample pieces are weighed. The sample piece suitably has a rectangular or circular shape with an area in the range 400-2000 mm ² . When measuring the thickness of a sample piece with a caliper, a pressure of 0.5 kPa is applied to the entire surface of the sample piece. The weight [m] of the sample piece, along with the thickness [t] and area [A], is determined by the formula ρ=m/At
is used to calculate the density [ρ] according to

In FIG. 1a, a second sample piece P2 of one or more product segments 2a is indicated by dotted lines for illustrative purposes, and in the illustrated embodiment the second sample piece P2 has a rectangular shape. ing. FIG. 1a shows a second area A2 and a second thickness direction T2 of a second sample piece P2.

As shown in FIG. 1b, the mold system S further densifies or compresses the residual section 2b to a first degree of compaction D _C1 that is higher than the degree of compaction D _C1 of the one or more product sections 2a. It may have a compact unit 11 formed as such. The compact unit 11 has a first compact roller 11a, which cooperates with a second compact roller 11b. Both compact rollers are arranged on opposite sides of the cellulose blank structure 2, and when the cellulose blank structure 2 is fed between the first compact roller 11a and the second compact roller 11b, the cellulose The blank structure 2 is compressed. As shown in FIG. 1b, the first compact roller 11a has a plurality of recesses 12 forming the product sections 2a, and the areas of the first compact roller 11a between the recesses 12 are relative to each other. The residual section 2b of the cellulose blank structure 2 is molded, which has a high degree of compaction. Each recess 12 has a shape and structure corresponding to the product category 2a. The recess 12 can be used to compress the product section 2a to a second degree of compression D _C2 , in which case the second degree of compression D _C2 is lower than the first degree of compression D _C1 . In an alternative embodiment, not shown, the second compacting roller 11b may be provided with recesses corresponding to the recesses 12 of the first compacting roller 11a for shaping the product section 2a.

The mold system S may furthermore have a cutting unit 9 configured to form one or more cutting patterns 4 in the cellulosic blank structure 2 . The cellulose blank structure 2 includes at least a A cutting pattern 4 may be arranged partially around each product section 2a in the residual section 2b and/or the transition section 2c. Each cutting pattern 4 partially separates, in the illustrated embodiment, the part of the cellulose blank structure 2 that is connected to the product section 2 a from the rest of the cellulose blank structure 2 . Each cutting pattern 4 forms at least one bridge structure 4a in the residual section 2b and/or the transition section 2c. The bridge structure 4a connects the part of the cellulose blank structure 2 connected to the product section 2a with the rest of the cellulose blank structure 2, as shown for example in FIGS. 5b to 5c and 6b. , allowing displacement of the part of the cellulose blank structure 2 connected to the product section 2a. The displacement facilitates the shaping of the cellulosic product 1 in one or more molds 3, especially if the cellulosic product 1 has a deep-drawn structure. The cutting pattern 4 may have any suitable structure for forming the bridge structure 4a.

The cutting unit 9 may be arranged as a separation unit upstream of one or more molds 3, as shown in Figure 2b, or as a separate unit, as shown in Figures 9a-9b. It may be arranged as one or more assemblies connected to the mold 3 described above. The cutting unit described below may be used with other embodiments of the mold system S.

In the embodiment shown in FIGS. 2b-2c, the cutting unit 9 is configured as a rotary die cutter 10. In the embodiment shown in FIGS. The illustrated rotary die cutter 10 has a die cutter 10a and an anvil roll 10b. The die cutter 10a has a plurality of cutting elements 10c that form a cutting pattern 4 in the cellulose blank structure 2 when the cellulose blank structure 2 is fed between the die cutter 10a and the anvil roll 10b. Therefore, the cutting element 10c has a structure corresponding to the shape of the cutting pattern 4. The rotary die cutter 10 may also function as a compacting roller in a manner similar to that described above in connection with FIG. 1b. As shown in FIG. 2b, the die cutter 10a has a plurality of recesses 12 forming the product sections 2a, and the regions of the die cutter 10a between the recesses 12 have a relatively high degree of compression. The remaining section 2b of the cellulose blank structure 2 is being molded. Each recess 12 has a shape and structure corresponding to the product category 2a. The recess 12 can be used to compress the product section 2a to a second degree of compression D _C2 , in which case the second degree of compression D _C2 is lower than the first degree of compression D _C1 . In an alternative embodiment, not shown, the anvil roll 10b may be provided with a recess corresponding to the recess 12 of the die cutter 10a for forming the product section 2a. With such a construction, the formation of one or more cutting patterns 4 and the compaction of the cellulose blank structure 2 are performed in a single operational step by the rotary die cutter 10.

The cutting unit 9 may also have another suitable construction. In the embodiment shown in FIGS. 9a-9b, the cutting unit 9 is configured as a press cutting device 20, which is arranged connected to the mold 3 of the mold system S. In the embodiment shown in FIGS. The press cutting device 20 cuts a cutting edge that forms a cutting pattern 4 on the cellulose blank structure 2 when the cellulose blank structure 2 is placed between the first mold part 3a and the second mold part 3b. It has a movably arranged common plate structure 20a with a plurality of cutting elements 20b. Similar to what has been described above, a cutting pattern 4 is formed at least partially around each product section 2a in a residual section 2b and/or a transition section 2c, so that the cutting elements 20b correspond to the shape of the cutting pattern 4. It has a structure that The plate structure 20a with cutting elements 20b is arranged connected to the second mold part 3b in the non-cutting position shown in FIG. 9a. In FIG. 9a, a preformed cellulose blank structure 2 with a product section 2a and a residual section 2b is arranged connected to a first mold part 3a. The press cutting device 20 furthermore has a pressure cylinder 20c arranged for displacing the plate structure 20a with the cutting elements 20b from the non-cutting position into the cutting position shown in FIG. 9b. In figure 9b, the cutting element 20b abuts an anvil structure 20d which is arranged connected to the first mold part 3a to form a cutting pattern 4 in the cellulosic structure. Anvil structure 20d may be formed from a flexible plate structure of a suitable material, for example polyurethane. Once the cutting pattern 4 has been formed in the cellulose blank structure 2, the plate structure 20a with the cutting elements 20b returns to the position shown in FIG. 9a, allowing the product forming operation to be carried out.

In a particular embodiment, each cutting pattern 4 has a first cutting 5 connected to and arranged around the corresponding product section 2a, in which case the first cutting 5 comprises: It has a first cutting line 5a with a first intermediate section 5b forming at least one bridge structure 4a.

In FIG. 7a, an exemplary spiral-shaped cutting pattern 4 is schematically shown, in which a first cutting 5 is connected to and arranged around the product section 2a. The first cutting section 5 has a first cutting line 5a which, as shown, has a first cutting line between the overlapping sections of the first cutting line 5a. 1 intermediate section 5b. The intermediate section 5b forms at least one bridge structure 4a.

In an alternative embodiment, each cutting pattern 4 has discontinuous first cuts 5 connected to and arranged around the corresponding product section 2a, and relative to the product section 2a: It has a discontinuous second cut section 6 disposed outside and around the discontinuous first cut section 5 . The discontinuous first cutting section 5 has one or more first cutting lines 5a, and the first cutting line has one line between the one or more first cutting lines 5a. It has two or more first intermediate sections 5b. The discontinuous second cutting part 6 has one or more second cutting lines 6a, and the second cutting line has one line between the one or more second cutting lines 6a. It has two or more second intermediate sections 6b. One or more first intermediate sections 5b and one or more second intermediate sections 6b form at least one bridge structure 4a.

In Figures 2c, 3a-3b, 4a-4b, 6b and 7b, an exemplary cutting pattern 4 is shown, which is connected to the corresponding product segment 2a. a discontinuous first cut 5 arranged around it and a discontinuous first cut 5 arranged around it outside the discontinuous first cut 5 relative to the product section 2a; It has a second cutting part 6. The discontinuous first cutting section 5 has a plurality of first cutting lines 5a, and the first cutting lines 5a include a first intermediate section 5b between the first cutting lines 5a. have. The discontinuous second cutting section 6 has a plurality of second cutting lines 6a, and the second cutting lines 6a include a second intermediate section 6b between the second cutting lines 6a. have. The first intermediate section 5b and the second intermediate section 6b form a bridge structure 4a. The first discontinuous cut 5 and the second discontinuous cut 6 may be arranged in a relatively overlapping relationship with each other, as shown, in which case the first discontinuous cut 5 and the second discontinuous cut 6 may The one or more first cutting lines 5a overlap the one or more second intermediate sections 6b, and the one or more second cutting lines 6a overlap the one or more first intermediate sections 5b. overlaps.

In an alternative embodiment, each cutting pattern 4 includes at least one non-continuous addition arranged outside and around the second non-continuous cut 6 relative to the product section 2a. It may further have additional cuts 7, in which case each of the at least one non-continuous additional cut 7 has one or more additional cutting lines 7a, The additional cutting lines have one or more additional intermediate sections 7b between one or more additional cutting lines 7a.

In FIG. 7c, an exemplary cutting pattern 4 is shown, which includes a non-continuous first cut 5 connected to and arranged around the corresponding product section 2a; a discontinuous second cut 6 arranged outside and around the discontinuous first cut 5 relative to the product section 2a; , and a discontinuous additional cut 7 arranged outside and around the second discontinuous cut 6 . The discontinuous additional cuts 7 have a plurality of additional cutting lines 7a, which additional intermediate sections 7b are formed between the additional cutting lines 7a. have. In FIG. 7d, an exemplary cutting pattern 4 is shown, which includes a non-continuous first cut 5 connected to and arranged around the corresponding product section 2a; a discontinuous second cut 6 arranged outside and around the discontinuous first cut 5 relative to the product section 2a; , and two additional discontinuous cuts 7 arranged outside and around the second discontinuous cut 6 . The first additional discontinuous cut 7:1 is arranged outside and around the second discontinuous cut 6 relative to the product section 2a and is A non-continuous second additional cut 7:2 is arranged outside and around the discontinuous first additional cut 7:1 relative to the product section 2a. . Each of the discontinuous additional cuts 7 has a plurality of additional cutting lines 7a, and these additional cutting lines have additional intermediate lines between the additional cutting lines 7a. It has section 7b.

In an alternative embodiment, instead of the above arrangement, each cutting pattern 4 has only non-continuous first cuts 5 connected to and arranged around the corresponding product section 2a. good. The discontinuous first cutting section 5 has one or more first cutting lines 5a, and the first cutting line has one line between the one or more first cutting lines 5a. It has one or more first intermediate sections 5b, the one or more first intermediate sections 5b forming at least one bridge structure 4a.

In FIG. 7e, an exemplary cutting pattern 4 is shown having only discontinuous first cuts 5 connected to and arranged around the corresponding product section 2a. The discontinuous first cutting section 5 has a plurality of first cutting lines 5a, and the first cutting lines 5a include a first intermediate section 5b between the first cutting lines 5a. have. The first intermediate section 5b forms a bridge structure 4a.

Each cut 5, 6, 7 extends suitably through the cellulose blank structure 2. In an alternative not shown embodiment, at least one of the intermediate sections 5b, 6b, 7b has a cut extending partially through the cellulose blank structure 2.

In an alternative not shown embodiment, some of the intermediate sections 5b, 6b, 7b may be of elongated design and may be configured to break during shaping of the cellulosic product 1. The slender structure of the intermediate sections 5b, 6b, 7b makes it possible to transport the cellulose blank structure 2 without being damaged or separated, for a reliable positioning of the cellulose blank structure 2 relative to one or more molds 3. It is possible.

As mentioned above, the mold system S comprises one or more molds 3, each mold 3 having a first mold part 3a and a second mold part 3a that cooperate with each other during the molding of the cellulosic product 1. It has a mold part 3b. The first mold part 3a and the second mold part 3b are arranged movably relative to each other, and the first mold part 3a and the second mold part 3b are movable relative to each other in the pressing direction D _P. It is configured to move. In the embodiment shown in FIGS. 5a to 5e, the second mold part 3b is stationary and the first mold part 3a is arranged movably relative to the second mold part 3b in the pressing direction D _P. There is. As indicated by the double-headed arrow in FIG. 5a, the first mold part 3a moves towards the second mold part 3b and towards the second mold part 3b in a linear movement along an axis extending in the pressing direction D _P. It is configured to move in both directions away from the mold part 3b.

In alternative embodiments, the first mold part 3a may be stationary and the second mold part 3b movably arranged relative to the first mold part 3a, or both mold parts may They may be arranged movably with respect to each other.

The mold system S may be of single cavity or alternatively multi-cavity construction. A single cavity mold system has only one mold 3 with first and second mold parts. A multi-cavity mold system has two or more molds 3, each with a first and second mold part. In Figures 1b and 2b, the mold system S is arranged as a multi-cavity mold system with a plurality of molds 3 with first and second mold parts, the movement of the mold parts being simultaneous Properly synchronized for molding operations. The parts of the mold system S shown in FIGS. 5a-5e and 6a-6c may represent a single-cavity structure, or alternatively a section of a multi-cavity structure. In the following, the mold system S is described with respect to a multi-cavity mold system, but the present disclosure is equally applicable to single-cavity mold systems.

For all embodiments according to the present disclosure, the expression movement in the pressing direction D _P includes movement along an axis extending in the pressing direction D _P , which movement is carried out in the opposite direction along this axis. Please understand that it is okay to do so. This representation further includes, for all embodiments, both linear and non-linear movements of the mold parts, in which case the mold parts are repositioned in the pressing direction D _P as a result of the movement during molding. Ru.

In order to form a cellulose product 1 from an air-formed cellulose blank structure 2 in a mold system S, an air-formed cellulose blank structure 2 is first provided from a suitable source. The cellulose blank structure 2 may be air formed from cellulose fibers and arranged in a rolled or laminated manner. The roll or laminate can then be connected and placed into a mold system S. Alternatively, the cellulose blank structure 2 may be air formed from cellulose fibers while connected to a mold system S and fed directly to the mold section.

The mold system S further comprises a feeding unit 8 configured to feed the cellulose blank structure 2 in a feeding direction _DF to a forming position F _POS in the mold system S. For example, as shown in FIGS. 1b, 2b, 5a to 5e, and 6a to 6c, the feeding unit 8 feeds the cellulose blank structure 2 in the feeding direction D _F into the first mold part. 3a and the second mold part 3b, it has one or more supply belts 8a used for conveying to the forming position _FPOS between the mold part 3a and the second mold part 3b. The feed belt 8a is further used to hold the cellulose blank structure in position during the forming process. The supply belt 8a may have any suitable structure for transporting the cellulose blank structures 2. In FIGS. 6a-6b, a supply belt 8a is shown schematically in a perspective view. The supply belt 8a may be vacuum type with suction passages 8b for holding the cellulose blank structure 2 during transport, as shown in Figures 6a to 6c.

In the embodiment shown in Figures 5a-5e and 6a-6c, a supply belt 8a is arranged on each side of the first mold part 3a. These supply belts 8a cooperate to transport the cellulose blank structure 2 to the forming position F _POS shown in FIG. 5a. At the molding position F _POS , the cellulose blank structure 2 is arranged between the first mold part 3a and the second mold part 3b. The feeding unit 8 may also have another suitable structure, such as a feeding roller.

The feeding unit 8 is feeding the cellulose blank structure 2 in the feeding direction _DF to the forming position F _POS in the mold system S. In the molding position F _POS , each product section 2a is arranged between a corresponding first mold part 3a and a second mold part 3b, as can be seen from FIGS. 1b and 2b. The product sections 2a are thus arranged on the cellulosic blank structure 2 in a pattern corresponding to the arrangement of one or more molds 3 in the mold system S, as shown in FIGS. 1b and 2b.

The first mold part 3a is arranged to mold the cellulosic product 1 by interaction with the corresponding second mold part 3b. During molding of the cellulose product 1, the cellulose blank structure 2 is subjected to a product molding pressure P _F of at least 1 MPa, preferably in the range from 4 to 20 MPa, and a product molding temperature in the range from 100°C to 300°C in each mold 3. exposed to temperature _TF . Therefore, by heating the cellulose blank structure 2 to a forming temperature T _F in the range of 100 to 300°C, and pressing the cellulose blank structure 2 at a forming pressure P _F in the range of 1 to 100 MPa, preferably 4 to 20 MPa. By doing so, the cellulose product 1 is molded from the cellulose blank structure 2 between each first mold part 3a and the corresponding second mold part 3b. When molding the cellulose product 1, strong hydrogen bonds are formed between the cellulose fibers in the cellulose blank structure 2 arranged between the first mold part 3a and the second mold part 3b. The temperature and pressure levels are measured in the cellulose blank structure 2, for example, during the molding process by suitable sensors arranged within or connected to the cellulose fibers within the cellulose blank structure 2.

When the cellulose blank structure 2 is placed in the forming position F _POS between the first mold part 3a and the second mold part 3b, the first mold part 3a is indicated by the arrow in FIG. 5b. As shown in _FIG . In figure 6b the position of the cellulose blank structure 2 in figure 5b is schematically shown in a perspective view, omitting the first mold part 3a for illustration purposes. In the forming position F _POS , before forming the cellulosic product 1, the residual section 2b and one or more product sections 2a are aligned in the pressing direction of the forming mold system S, as schematically shown in Figure 6b. _DP can be at least partially displaced relative to each other. When the first mold part 3a is moved towards the second mold part 3b, the cellulose blank structure 2 is compressed between the mold parts. In the position shown in FIG. 5d, the first mold part 3a is moved further towards the second mold part 3b and reaches the product forming position, in which the cellulose blank structure 2 is applied with a forming pressure P _F and a forming temperature T _F are applied. During the molding of the cellulose product 1, the cellulose A molding cavity C for molding the product 1 is formed between the first mold part 3a and the second mold part 3b. A molding pressure P _F and a molding temperature T _F are applied to the cellulose blank structure 2 in each molding cavity C. The shaping of the cellulosic product 1 may further include a cutting operation, in which case the cellulosic product 1 is cut out of the cellulose blank structure 2 in the mold system S during the shaping of the cellulosic product 1. For example, a cutting device can be arranged in the mold part for such an operation. When the cellulose product 1 is molded in the mold system S, the first mold part 3a is moved away from the second mold part 3b, as indicated by the arrow in Figure 5e, and the cellulose product 1 can be ejected from the mold system S as shown in Figure 6c, for example using an ejector rod or similar device.

5c-5d show the position of an exemplary mold system S during an edge forming operation for forming the edge structure 1a of the cellulosic product 1. In FIGS. An edge forming operation may be used instead of a cutting operation to separate the cellulosic product 1 from the cellulosic blank structure 2 and at the same time form the edge structure 1a. Each first mold part 3a includes an edge forming device 14 with protruding elements 14a configured to compress and separate the fibers of the cellulosic blank structure 2. An edge section 14b facing the second mold part 3b is arranged on the projecting element 14a. The protruding elements 14a are suitably arranged as continuous elements extending around the edge forming device 14, the protruding elements 14a following the edge shape or contour of the cellulosic product 1 produced in the mold system S. has a corresponding extension. However, it is to be understood that the projecting elements 14a may have any suitable extension, for example discontinuous, depending on the shape of the cellulosic product 1 to be formed. The projecting element 14a may furthermore have a pointed cross-sectional structure with an edge section 14b, as shown in FIG. 5d. The projecting element 14a with the edge section 14b may have another suitable cross-sectional structure, such as a rounded edge section or a flat edge section, in another embodiment not shown. .

The edge forming device 14 may be arranged movably relative to the base structure of the first mold part 3a, as shown in FIGS. 5a to 5e, the edge forming device 14 The pressure member is adapted to interact with a pressure member located on the body. The edge forming device 14 may have any suitable shape and structure depending on the shape and structure of the cellulosic product 1. The edge forming device 14 may, for example, be arranged so as to be slidable relative to the base structure in the pressing direction _DP . The pressure member may include one or more springs 14c disposed between the base structure and the edge forming device 14. The pressure member may alternatively be arranged as a hydraulic or pneumatic device. In an alternative, not shown embodiment, the edge-forming device 14 may be constructed as a stationary structure with a projecting element 14a arranged on the first mold part 3a. Alternatively to this arrangement, the edge forming device may be arranged in the second mold part 3b or in both the first mold part 3a and the second mold part 3b.

During the movement of the first mold part 3a towards the second mold part 3b, the protruding elements 14a of each edge forming device 14 cause the cellulose blank structure 2 to become Some of the fibers of structure 2 are separated. As shown in Figures 5c to 5d, when the first mold part 3a reaches the second mold part 3b, the stopper member 14d arranged on each edge forming device 14, as shown in Figure 5d, This prevents direct contact between the projecting element 14a and the second mold part 3b during the molding of the compressed edge structure 1a. In the embodiment shown in FIGS. 5a to 5e, the stop member 14d is arranged as a protrusion on the edge forming device 14 with an extension in the pressing direction D _P that is greater than the extension of the protrusion element 14a. There is. When the first mold part 3a reaches the second mold part 3b, each stopper member 14d comes into contact with the corresponding second mold part 3b, as shown in FIGS. 5c to 5d, and presses in the pressing direction D _P Due to the greater extension at , a direct contact between the projecting element 14a and the second mold part 3b is prevented. The cutting pattern 4 in the cellulose blank structure 2 forms an opening in the cellulose blank structure 2 and, as can be seen from Figure 5d, between each stopper member 14d and the corresponding second mold part 3b. allows for direct contact. Stop member 14d may be arranged as a continuous element extending around each edge forming device 14, or alternatively as one or more projections extending from each edge forming device 14. Instead of such a configuration, the stopper member 14d may be arranged in the second mold part 3b or in both the first mold part 3a and the second mold part 3b.

Each stop member 14d prevents contact between the protruding element 14a and the corresponding second mold part 3b during the molding of the compressed edge structure 1a, with this arrangement the protruding element 14a is prevented from contacting the corresponding second mold part 3b. It is placed at a small distance from part 3b. A small gap is formed between the protruding element 14a and the second mold part 3b. As the first mold part 3a moves further towards the second mold part 3b, the edge forming device 14 is pushed into the first mold part 3a and reaches the edge forming position shown in Figure 5d. Ru. When the edge forming device 14 is pushed into the first mold part 3a, the edge structure 1a of the cellulosic product 1 is formed. When the edge structure 1a is molded, the fibers of the cellulose blank structure 2 collect in the area between each projecting element 14a and the corresponding second mold part 3b. At the same time, an edge forming pressure P _EF and an edge forming temperature T _EF are applied to the cellulose blank structure 2 . When an edge forming pressure P _EF and an edge forming temperature T _EF are applied to the cellulose blank structure 2, a highly compressed edge structure 1a is formed. The edge structure 1a is suitably shaped as a thin edge extending around the periphery of the cellulosic product 1, and the highly compressed shaped edge structure 1a prevents delamination of the cellulosic product 1. and efficiently prevent moisture absorption into the cellulose product 1. A high edge forming pressure _PEF is applied to the cellulose blank structure 2 at a small distance between each edge section 14b and the corresponding second mold part 3b, resulting in a very thin compacted cellulose structure. is molded, and such a cellulosic structure can be used to easily separate the cellulosic product 1 and the cellulose blank structure 2 outside the mold section. The highly compacted thin cellulose structure is exposed to high compressive stresses during the edge forming operation, and during the edge forming process, the energy stored in the cellulosic structure, high tension and/or tensile stress When high pressure levels are applied to the cellulose fibers at the edge forming pressure P _EF , the cellulose fibers break. The residual fibers in the cellulose blank structure 2 remaining after forming the cellulosic product 1 may be recycled. The edge forming operation, along with the product forming operation, is performed by the edge forming device 14.

A suitable edge forming pressure P _EF to be applied to the cellulose blank structure 2 during forming of the edge structure 1a is at least 10 MPa, preferably in the range 10 to 4000 MPa, or more preferably in the range 100 to 4000 MPa. A suitable edge forming temperature T _EF applied to the cellulose blank structure 2 during forming of the edge structure 1a is in the range 50-300°C, preferably in the range 100-300°C.

A deformation element E for establishing the product molding pressure may be arranged connected to each first mold part 3a and/or second mold part 3b. In the embodiment shown in Figures 5a to 5e, the deformation element E is attached to the first mold part 3a. By using the deformation element E, the molding pressure P _F can be an isostatic molding pressure.

For all embodiments, the first mold part 3a and/or the second mold part 3b may have a deformation element E, which during the molding of the cellulosic product 1 inside the molding cavity C. It is configured to apply a molding pressure _PF to the cellulose blank structure 2. The deformation element E may be attached to the first mold part 3a and/or the second mold part 3b by suitable attachment means, for example adhesive or mechanical fastening means. During the molding of the cellulose product 1, the deformation element E is deformed to apply a molding pressure P _F to the cellulose blank structure 2 in the mold cavity C, so that the deformation of the deformation element E causes the cellulose product 1 to form a complex three-dimensional structure. Even if the cellulose blank structure 2 has a variable thickness, an even pressure distribution is achieved. In order to apply the required forming pressure P _F to the cellulose blank structure 2, the deformation element E is formed from a material that can be deformed when a force or pressure is applied, and the deformation element E has a size and a size after deformation. Suitably formed from a resilient material capable of recovering its shape. The deforming element E may furthermore be made of a material with suitable properties to withstand the high molding pressures P _F and molding temperatures T _F levels used during molding of the cellulosic product 1.

Certain elastic or deformable materials have fluid-like properties when exposed to high pressure levels. If the deformation element E is formed from such a material, an even pressure distribution can be achieved in the molding process, in which case the pressure exerted by the deformation element E on the cellulose blank structure 2 in the molding cavity C are equal or substantially equal in all directions between the mold parts. If, under pressure, each deformation element E is in a fluid-like state, a uniform fluid-like pressure distribution is achieved. A forming pressure P _F is therefore applied by such material to the cellulosic blank structure 2 from all directions, and the deforming element E thus exerts an isostatic forming pressure during the forming of the cellulosic product 1. Pour onto cellulose blank structure 2. Each deformation element E may consist of a suitable structure of elastic material, by way of example the deformation element E consists of silicone rubber, polyurethane, polychloroprene or rubber, with a hardness in the range from 20 to 90 Shore A. It may be formed from a solid or substantially solid structure. Other materials for the deformation element E may be, for example, suitable gel materials, liquid crystal elastomers and MR fluids.

The mold system S further includes a heating unit. The heating unit is configured such that a forming temperature T _F is applied to the cellulose blank structure 2 in each forming cavity C. The heating unit is further suitably configured such that an edge forming temperature T _EF is applied to the cellulosic blank structure 2 during an edge forming operation. The heating unit may have any suitable construction. A suitable heating unit, for example a heated mold section, can be used to generate the forming temperature T _F and the edge forming temperature T _EF . The heating unit may be integrated or cast into the first mold part 3a and/or the second mold part 3b, suitable heating devices being, for example, electric heaters such as resistor elements or It is a fluid heater. Other suitable heat sources can also be used.

In Figure 8a an alternative embodiment of a cellulose blank structure 2 is schematically shown. The cellulose blank structure 2 has one or more defined product sections 2a and a residual section 2b, where the residual section 2b is arranged in connection with one or more product sections 2a. There is. Before the forming operation in the mold system S, the residual section 2b is compressed to a first degree of compression D _C1 which is higher than the degree of compression D _C of the one or more product sections 2a, as can be seen from the figure. . Cellulose blank structure 2 further comprises one or more transition sections 2c arranged between one or more product sections 2a and residual sections 2b. In the transition section 2c, the degree of compression changes between a first degree of compression D _C1 and a degree of compression D _C of one or more product sections 2a. In this embodiment _{, one or more product segments 2a may be compressed to a second degree of compression D C2, in which case the first degree of compression D C1 is} higher than the second degree of compression D _C2 . Each section may have a density as described above.

The construction of the cellulose blank structure 2 in FIGS. 1a, 2a and 8a may be fed to the forming position F _POS using the feeding unit 8 described above. In an alternative embodiment shown in FIGS. 8b to 8c, instead of the configuration described above, the feeding unit 8 has a tractor feed structure for transporting the cellulose blank structures 2 to the feeding position F _POS . ing. The feeding unit 8 has a first roller 15a and a cooperating second roller 15b, between which the cellulose blank structure 2 is arranged as shown in FIG. 8b. be done. A first roller 15a and a second roller 15b are compressing the cellulose blank structure 2 to form a product section and a residual section 2b. The first roller 15a has a recessed portion 16a for forming the product section 2a in a manner similar to that described with respect to FIGS. 1b and 2b. A non-recessed portion 16b of the first roller 15a is arranged to form a residual section 2b on each side of the recessed portion 16a. Following the recessed portion 16a, the first roller 15a, in the non-recessed portion 16b, punches a plurality of holes for forming tractor feed holes 18 arranged in the rows R of the cellulose blank structure 2. It has a cutter 17. Tractor feed hole 18 is used to transport cellulose blank structure 2. In the embodiment shown in FIG. 8b, the first roller 15a is provided with five rows of punching cutters 17 arranged on each side of the respective recessed portion 16a. In this way, the hole cutter 17 forms five rows R of tractor feed holes 18 in the cellulose blank structure 2. The feeding unit 8 further comprises a sprocket wheel 19 used to feed the cellulose blank structure 2 to the feeding position F _POS , the sprocket in this case engaging the tractor feed hole 18 . In FIG. 8c, the first roller 15a and the second roller 15b are shown in more detail together with the plurality of hole cutters 17. In FIG. The hole cutter 17 is arranged as a sharp protrusion that cuts out a tractor feed hole 18 in the cellulose blank structure 2. The tractor feed holes 18 are partially cut out by a hole cutter, as shown in the enlarged partial view of the cellulose blank structure 2 in FIG. Can be cut. Tractor feed hole 18 engages sprocket wheel 19 during the feeding operation. The cut tractor feed hole 18 has a hinge-like structure to hold a cut-out piece of fibrous material 18a connected to the cellulosic blank structure 2, as shown in Figure 8b. A connecting portion 18b may be arranged. The rotational arrangement of the connecting part 18b with respect to the partially cut tractor feed hole 18 is shown in the enlarged part of the cellulose blank structure 2 in FIG. There may be alternation in the cutting pattern as shown. In FIG. 8b, the connecting portions 18b of two adjacent tractor feed holes 18 are arranged on opposite sides with respect to each tractor feed hole 18.

The present disclosure has been presented above with specific embodiments. However, other embodiments than those described above are possible and within the scope of this disclosure. Different method steps than those described above may be provided within the scope of this disclosure, implementing the method by hardware or software. Thus, according to an exemplary embodiment, a non-transitory computer-readable storage medium storing one or more programs configured to be executed by one or more processors of a control unit of mold system S is provided. The one or more programs provided include instructions for performing a method according to any one of the embodiments described above. Alternatively, according to another example embodiment, a cloud computing system may be configured to perform any of the method aspects presented herein. A cloud computing system can include distributed cloud computing resources that collectively perform aspects of the methods presented herein under the control of one or more computer program products. Additionally, the processor may be connected to one or more communication interfaces and/or sensor interfaces for receiving and/or transmitting data to external entities, such as sensors, off-site servers, or cloud-based servers.

The processor of mold system S may be or include any number of hardware components for performing data or signal processing or for executing computer code stored in memory. You can stay there. The system may have an associated memory, the memory being one or more devices for storing data and/or computer code to complete or facilitate various methods described herein. It may be. Memory can include volatile memory or non-volatile memory. Memory may include database components, object code components, script components, or any other type of information structure to support the various activities herein. According to example embodiments, any distributed or local memory device may be utilized with the systems and methods herein. According to an exemplary embodiment, the memory is communicatively connected to the processor (e.g., via circuitry or any other wired, wireless, or network connection) and described herein. Contains computer code for executing one or more processes.

It will be understood that the above description is merely exemplary in nature and is not intended to limit the application or use of the present disclosure. Although specific examples are described in the specification and shown in the drawings, those skilled in the art will appreciate that various modifications may be made without departing from the scope of the disclosure as defined by the claims. , and that equivalents may be used in place of that element. In addition, modifications may be made to adapt a particular situation or material to the teachings of the disclosure without departing from its essential scope. Accordingly, the scope of this disclosure is not limited to the specific examples shown in the drawings and described in the specification as the best mode presently contemplated for carrying out the teachings of this disclosure; It is intended to include any embodiment within the scope of the foregoing description and appended claims. Reference signs in the claims shall not be construed as limiting the scope of matter protected by the claims; their sole function is to facilitate understanding of the claims.

1 Cellulose product 1a Edge structure 2 Cellulose blank structure 2a Product division 2b Remaining division 2c Transition division 3 Molding mold 3a First mold part 3b Second mold part 4 Cutting pattern 4a Bridge structure 5 First cutting part 5a First 1 cutting line 5b first intermediate section 6 second cutting section 6a second cutting line 6b second intermediate section 7 additional cutting section 7a additional cutting line 7b additional intermediate section 8 feeding unit 8a Supply belt 8b Suction passage 9 Cutting unit 10 Rotary die cutter 10a Die cutter 10b Anvil roll 11 Compact unit 11a First compact roller 11b Second compact roller 12 Recess 14 Edge forming device 14a Projecting element 14b Edge section 14c Spring 14d Stopper Member 15a First roller 15b Second roller 16a Recessed portion 16b Non-recessed portion 17 Hole cutter 18 Tractor feed hole 18a Cutout piece 18b Connection portion 19 Sprocket wheel 20 Press cutting device 20a Plate structure 20b Cutting Element 20c Pressure cylinder 20d Anvil structure C Molding cavity D _C1 First degree of compression D _C2 Second degree of compression D _F supply direction D _P press direction E Deformation element F _POS molding position P _EF edge molding pressure P _F molding pressure R row T _EF edge molding temperature T _F molding temperature S mold system

Claims (19)

A method for forming a cellulose product (1) from an air-formed cellulose blank structure (2) in a mold system (S), said mold system (S) comprising one or more molds (3). ), each mold (3) having a first mold part (3a) and a second mold part (3b) configured to cooperate with each other during molding of said cellulosic product (1). ), and the method includes the following steps:
providing said cellulose blank structure (2), said cellulose blank structure (2) having one or more product sections (2a) and surrounding said one or more product sections (2a) or said one or more product sections (2a); a residual section (2b) arranged connected to the product section (2a) of;
compressing at least a portion of said residual section (2b) to a first degree of compression (D _C1 ) higher than the degree of compression (D _C ) of said one or more product sections (2a);
feeding said cellulose blank structure (2) in a feeding direction (D _F ) to a forming position (F _POS ) in said mold system (S), in said forming position (F _POS ) each product segment is (2a) is arranged between a corresponding first mold part (3a) and a second mold part (3b);
By heating the cellulose blank structure (2) to a forming temperature (T _F ) in the range of 100 to 300° C., and heating the cellulose blank structure (2) to a forming temperature (T F ) in the range of 1 to 100 MPa, preferably 4 to 20 MPa. The cellulose product (1) is removed from the cellulose blank structure (2) between the first mold part (3a) and the second mold part (3b) by pressing at a forming pressure (P _F ). a step of forming;
How to have. The cellulose blank structure (2) further comprises one or more transition sections (2c) arranged between the one or more product sections (2a) and the residual section (2b), In said one or more transition segments (2c), the degree of compression is between said first degree of compression (D _C1 ) and said degree of compression (D _C ) of said one or more product categories (2a). 2. The method of claim 1, wherein: The method comprises subjecting at least a portion of the one or more product sections (2a) to a second degree of compaction (D _C2 ) before feeding the cellulose blank structure (2) to the forming position (F _POS ). 3. The method according to claim 1 or 2, further comprising a step of compressing to a maximum of ), wherein the first degree of compression (D _C1 ) is higher than the second degree of compression (D _C2 ). The method includes, before molding the cellulosic product (1), at the molding position (F _POS ), the residual section (2b) and the one or more product sections (2a) in the mold system. 4. The method according to claim 1, further comprising at least partially displacing the (S) relative to each other in the pressing direction ( _DP ). The method comprises the step of arranging a cutting pattern (4) at least partially around each product section (2a) in said residual section (2b) and/or said transition section (2c), the method comprising: 4) at least one bridge structure (4a) for keeping each product section (2a) partially connected to said residual section (2b) and/or said transition section (2c) to said residual section (2b). ) and/or the transition section (2c). Each cutting pattern (4) has a discontinuous first cut (5) connected to and arranged around the corresponding product section (2a), said discontinuous first cut The cutting part (5) has one or more first cutting lines (5a), and the first cutting line is between the one or more first cutting lines (5a). 4. The method of claim 1, further comprising one or more first intermediate sections (5b), said one or more first intermediate sections (5b) forming said at least one bridge structure (4a). 5. The method described in 5. Each cutting pattern (4) has a first cutting section (5) connected to and arranged around the corresponding product section (2a), said first cutting section (5) comprising: 6. The method according to claim 5, comprising a first cutting line (5a) with a first intermediate section (5b) forming the at least one bridge structure (4a). Each cutting pattern (4) has a non-continuous first cut (5) connected to and arranged around the corresponding product section (2a) and relative to said product section (2a). 6. The method according to claim 5, further comprising a second discontinuous cut (6) arranged outside and around the first discontinuous cut (5). The discontinuous first cutting section (5) has one or more first cutting lines (5a), and the first cutting line is connected to the one or more first cutting lines (5a). having one or more first intermediate sections (5b) between the lines (5a), said non-continuous second cuts (6) having one or more second cutting lines (5a); 6a), said second cutting line having one or more second intermediate sections (6b) between said one or more second cutting lines (6a); 9. The method according to claim 8, wherein the one or more first intermediate sections (5b) and the one or more second intermediate sections (6b) form the at least one bridge structure (4a). Method. The discontinuous first cutting section (5) and the discontinuous second cutting section (6) are arranged in a relatively overlapping relationship with each other, and in this case, The first cutting line (5a) overlaps the one or more second intermediate sections (6b), and the one or more second cutting lines (6a) overlap the one or more second intermediate sections (6b). 10. The method according to claim 9, overlapping said first intermediate section (5b). Each cutting pattern (4) includes at least one non-continuous cut located outside and around said second non-continuous cut (6) relative to said product section (2a). further comprising additional cuts (7), each of said at least one non-continuous additional cuts (7) comprising one or more additional cutting lines (7a); 10. Claims 8 to 10, wherein the additional cutting lines have one or more additional intermediate sections (7b) between the one or more additional cutting lines (7a). The method described in any one of the above. 12. The method according to claim 6, wherein each cut (5, 6, 7) extends through the cellulose blank structure (2). Any of claims 6 to 12, wherein at least one of the intermediate sections (5b, 6b, 7b) has a cut extending partially through the cellulose blank structure (2). The method described in Section 1. The method comprises placing, by a cutting unit (9), said one or more cutting patterns (4) in said residual section (2b) and/or said transition section (2c) around each product section (2a). 14. A method according to any one of claims 5 to 13, further comprising the step. The cutting unit (9) is arranged as a rotary die cutter (10), and the method comprises:
forming the one or more cutting patterns (4) and compressing at least a portion of the residual section (2b) by the rotary die cutter (10) in a single operational step; or forming the one or more cutting patterns (4) and compressing at least a part of the residual section (2b) and compressing the one or more product sections by a cutter (10) in a single operational step; 15. The method of claim 14, further comprising compressing at least a portion of (2a). 1 . The method further comprises the step of cutting the cellulosic product ( 1 ) from the cellulose blank structure ( 2 ) in the mold system (S) during molding of the cellulosic product ( 1 ). 15. The method according to any one of 15 to 15. The one or more product sections (2a) are arranged on the cellulose blank structure (2) in a pattern corresponding to the arrangement of the one or more molds (3) in the mold system (S). 17. A method according to any one of claims 1 to 16. A mold system (S) for molding a cellulosic product (1) from an air-formed cellulose blank structure (2), said cellulose blank structure comprising one or more defined product categories (2a). ) and a defined residual section (2b) arranged surrounding or connected to said one or more product sections (2a); The mold system (S) comprises one or more molds (3), each mold (3) having a plurality of molds configured to cooperate with each other during molding of said cellulosic product (1). It has a first mold part (3a) and a second mold part (3b),
The mold system (S) is configured to compress at least a portion of the residual section (2b) to a first degree of compression (D _C1 ) higher than the degree of compression (D _C ) of the one or more product sections (2a). a compact unit (11) configured to compress the cellulosic blank structure ( ₂ ) _to a _supply unit (8) configured to further comprising a supply unit (8) arranged between;
Said one or more molds (3) are adapted to heat said cellulose blank structure (2) by heating said cellulose blank structure (2) to a forming temperature (T _F ) in the range of 100 to 300°C; The cellulose blank is pressed between the first mold part (3a) and the second mold part (3b) by pressing at a forming pressure (P _F ) in the range of 1 to 100 MPa, preferably 4 to 20 MPa. configured to form the cellulosic product (1) from the structure (2);
Molding mold system (S). A cellulose blank structure (2) for forming a cellulosic product (1) in a mold system (S), said cellulose blank structure (2) being air formed and having one or more defined a product segment (2a) and a defined residual segment (2b) arranged surrounding or connected to said one or more product segments (2a); at least a portion of the residual section (2b) has a first degree of compression (D _C1 ) higher than the degree of compression (D _C ) of the one or more product sections (2a); The cellulose blank structure (2) includes:
one or more transition sections (2c) arranged between said one or more product sections (2a) and said remainder section (2b), in said transition section (2c) the degree of compaction is equal to said one or more transition segments (2c) varying between a first degree of compression (D _C1 ) and said degree of compression (D _C ) of said one or more product segments (2a);
a cutting pattern (4) in said residual section (2b) and/or said transition section (2c) at least partially around each product section (2a), each cutting pattern (4) comprising said residual section (2a); (2b) and/or a cutting pattern (4) forming at least one bridge structure (4a) in said transition section (2c).

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